Rebuild of passenger rear-sill, floor areas and whatever else needed it at the time!
I carved away as much rust as was necessary here -
to be able to weld to what was left.
This was not always the case as what was left is often
much thinner than you see; it looks OK but the welder just
burns it away like butter, meaning you have to fill.
The rear floor needed attention, mainly in the areas where
the plastic plugs are situated especially under the seat mounting brackets.
The corner beside the rear seat bracket had to be rebuilt.
Tricky but possible. The rear of the rocker-panel was very similar
to the driver-side experience. This was reconstructed with 1mm sheet steel.
The outer sill part needed more attention what with all those bends
and the rear flange. Looks good though when done.
The plate for the rear section of the sill was attached by
driling holes and welding through to the flanges on the inner
and outer pieces already in position.
A couple of extra pieces were used here to to complete the corner
area and some rust spreading up around the wheel-arch.
Putting in the last piece of the floor. Gratifying work that.
You actually feel like you've achieved something after all those
long nights of hard labour. Difficult to keep the piece true as it is
fairly long and being 1mm out at one end can make a big difference to
the fit at the other end. When welding such a large piece,
it helps to spot-weld it in many places to hold it firm, else it will warp;
fitting the outrigger below could then be even more fun.
Prepare the outrigger as well as you can as you'll never see the insides of it again.
Welding upside-down, now that's a laugh.
(left) Typical rust spot behind rear wheelarch.
Hardest part here is the access for a suitable cutting tool.
Very strong when done though.